Positive Stop Control
Prod. No.: 7480-0050, Part No.: 77420
Dimensions: 12 1/4" wide x 6 1/4"deep x 17 3/4" high
Weight: 57 lbs. (with stand)
Pump Specifications
All pumps maximum rated working pressure: 10,000 psi
Shop Air Pump
Prod. No.: 7481-0002, Part No.: 77820
Weight: 10 lbs.
Hand Pump
Prod. No.: 7481-0006, Part No.: 77821
Weight: 25.6 lbs.
1/4 H.P. 12 Volt DC Pump
Prod. No.: 7481-0037, Part No.: 77439
Weight: 20.5 lbs.
1/4 H.P. 115 Volt AC Pump
Prod. No.: 7481-0033, Part No.: 77440
Weight: 20 lbs.
1/2 H.P. 115 Volt AC Pump
Prod. No.: 7481-0034, Part No.: 77441
Weight: 32 lbs.
1-1/2 H.P. 115 Volt AC Pump
Prod. No.: 7481-0035, Part No.: 77442
Weight: 108 lbs.
Carefully read and understand the following warnings before operating this crimper.
WARNING!
An incorrect hose assembly can rupture or blow apart in use, resulting in serious injury, death
or property damage. REMEMBER: Others depend on you to make correct assemblies.
FOR SAFETY’S SAKE
USE THIS MACHINE ONLY IF YOU:
1. Receive hands-on TRAINING with the MobileCrimp® 4-20 and Gates assemblies.
2. Follow current GATES OPERATING MANUAL AND CRIMP DATA for the MobileCrimp 4-20.
3. Use only NEW (UNUSED) GATES hose and fittings.
4. Wear SAFETY GLASSES.
5. KEEP HANDS CLEAR OF MOVING PARTS. Support hose with one hand while activating
pump with other hand.
6. DO NOT operate pump UNLESS cylinder is locked in crimp position.
7. To avoid risk of injury, DO NOT use crimper UNLESS CONTROLLER BASE PLATE is in place.
8. DO NOT operate crimper in horizontal position.
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MobileCrimp
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Serial No. _______________
(Located on front top of cylinder)
Date of Purchase _________
Contents
Identification List ...........................................................................................2
Setup ..............................................................................................................3
Hose Preparation ............................................................................................6
Operating Instructions ....................................................................................8
Measuring and Adjusting the Crimp Diameter ..............................................12
Maintenance .................................................................................................13
Troubleshooting ............................................................................................14
Replacement Parts List ..................................................................................15
Warranty ................................................................................inside back cover
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MobileCrimp
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1
Identification
List
Spacer Rings
Molykote and Brush
Die
Pressure Plate
Stand
Crimper
Hose Assembly
Clamps
Literature Packet
Magnet
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MobileCrimp
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Setup
1.
• Replace spacer, flat washers and knobs.
Do not tighten knobs.
Unpack carton.
• Remove crimper, pressure plate (1),
nylon-covered hose assembly (1),
literature envelope (1), stand (2 pieces),
magnet (1) and Molykote lubricant (1)
from shipping carton. Locate the serial
number assigned to the crimper on the
top front of the cylinder and record on
page one for future reference.
2.
Attach crimper to the stand.
• Place crimper on flat, well-supported
surface (such as the top of a workbench
or the bed of a service vehicle) with the
handle to the right.
Left Side
spacer
• Remove two (2) knobs, flat washers (2)
and spacer (1) from crimper pivot bolts.
Right Side
• Lift crimper and allow stand to swing
down onto the surface. Tighten knobs.
• Slide the two halves of the stand
together and attach to the crimper
at the pivot bolts.
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MobileCrimp
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3
3.
4.
Fasten crimper to work surface
before use (to avoid damage to
machine or personal injury because
an unsecured machine can fall).
• Position crimper so that mounting holes
are approximately 7" to 8" from the
edge of the work surface.
Attach pump to crimper.
• Place pump near crimper.
• Connect hose assembly to the pump
port (3/8" NPT threads). Pipe sealant
may be used to seal connection. (For
best connection, use Gates’ Quick
Disconnect couplings, G95311-0606
and G95321-0600, sold separately.)
• Mark the drilling location using the
mounting holes as a guide (see illustration below).
Edge of
work
surface
(2) 5/16" diameter holes
7 1/2"
11"
• Drill two 5/16" diameter holes.
• Use mounting holes or clamps to fasten
stand to work surface.
• Connect opposite end to the adapter
on crimper.
clamps
5.
Check pump oil level.
• Pump comes with oil in reservoir.
mounting holes
• Check proper oil level per pump
operating manual instructions or the
Maintenance Section (p. 13) of this
manual.
4
To avoid damage to
the machine or injury
to you, ALWAYS fasten
the crimper to the work
surface before you attempt to crimp.
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MobileCrimp
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6.
8.
Connect pump to power outlet.
• For 115V connection, plug power cord
into a properly grounded and rated circuit
(see inside cover for circuit requirements).
Place crimper in comfortable
working position.
• See photo below for suggested working
position.
• For vehicle battery connection, see
pump operating manual.
7.
Bleed air from system.
• Tilt crimper forward so adapter is at
its highest point.
IMPORTANT
Do not operate crimper in
horizontal position because
dies will become unstable.
• Turn pump on by pressing and holding
the power ”on“ switch, (see pump
operating manual for switch location)
which extends the ram.
Note: It’s a good
idea to place a
rubber mat on the
floor near the crimper
to reduce the chance of damaging a die if dropped and improve
operator comfort.
• Extend the ram approximately 1".
Release “on” switch allowing ram
to fully retract.
• Repeat a minimum of five (5) times to
bleed air completely.
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MobileCrimp
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5
Hose Preparation
MegaCrimp® Pre-Assembled
Couplings.
CAUTION
4.
Insert coupling into the hose until
the mark lines up with the end of
the coupling ferrule.
5.
Hose and coupling are now ready
for crimping.
A new hose and end fittings
(stem/ferrule) must be used
when building a hose assembly.
Re-using any components will
seriously affect performance and
could result in serious injury or
property damage.
1. Cut hose to desired length.
2. Using Gates crimp data chart #35019
(Ind), 428-7365 (Auto), select the
correct coupling or visit our website
to download our electronic program
at www.gates.com/ecrimp.
3.
Place a visible mark on hose cover
at the insertion length shown on the
crimp data chart.
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MobileCrimp
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GlobalSpiral™ Two-Piece Couplings.
Hose should be flush against stem
shoulder (see cutaway drawing below).
CAUTION
A new hose and end fittings
(stem/ferrule) must be used
when building a hose assembly.
Re-using any components will
seriously affect performance and
could result in serious injury or
property damage.
1.
2.
Cut hose to desired length.
Using Gates crimp data chart #35019(Ind), 428-7365 (Auto), select the
correct stem and ferrule or visit our
website to download our electronic
program at www.gates.com/ecrimp.
3.
4.
Place ferrule over end of hose.
5.
Clamp stem in vise on hex portion,
and push hose onto stem.
Lubricate the first two or three
serrations on stem with lightweight
oil (SAE 10W).
6.
Hose and coupling are now ready
for crimping.
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MobileCrimp
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Operating
Instructions
1.
• Using the magnet, place the die set
into the die cone.
Select correct die set.
• Using Gates crimp data chart #35019
(Ind), 428-7365 (Auto) or ecrimp, select
correct die set for the hose and coupling
being crimped.
die set
• Remove magnet by lifting the ”T”
handle, making sure the top of the
die fingers are even.
2.
Lubricate and load die.
• Swing cylinder to ”die loading” position.
• Apply thin layer of Molykote* lube
to the inside surface of the die cone.
Re-apply lube whenever surface
becomes shiny.
• Apply a thin layer of Molykote lube
to the top of the die set.
Important Note:
Lubricants should be
reapplied to metal-tometal sliding surfaces
whenever the surface becomes shiny.
Failure to do this reduces the life of
the dies and cone. Excessive wear on
these components produces poorly
performing hose assemblies that
could blow apart and result in injury.
* Use only Gates Molykote lube for proper operation
or Gates-recommended grease.
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MobileCrimp
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3.
4.
Select correct spacer.
Install spacer and pressure
plate.
• Place the spacer into the pressure plate.
• Using Gates crimp data chart #35019
(Ind), 428-7365 (Auto) or ecrimp, select
correct spacer for the hose and coupling
being crimped.
spacer
• Place the pressure plate (with spacer)
onto the die set.
Spacer must be located between pressure
plate and die set.
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MobileCrimp
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• When crimping bent tube and blockstyle couplings, keep thread end aligned
with notch in pressure plate and spacer.
5.
Insert hose assembly.
• Insert assembly from the bottom of the
die cone up through the die set.
6. Swing cylinder into crimping
• Locate the top of the ferrule
approximately 1/16"below the
top of the die set.
position.
• Using the handle, swing cylinder
toward you and lock into place with
lock pin.
IMPORTANT
For GS couplings, make sure
the top of the ferrule rests
against the hex or round
shoulder of the coupling.
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MobileCrimp
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• Make sure cylinder is locked into position by placing lock pin into hole on
top of cylinder.
CAUTION
Keep away from all moving parts!
If bodily contact with a moving part
occurs, immediately release the
pump power “on“ switch.
lock pin
IMPORTANT
Serious injury and/or crimper
damage can result if the cylinder
is not locked in its crimp position.
Incorrect
Correct
• When pressure plate contacts the top
of the die cone, release the power “on”
switch. Crimp is now complete.
7.
Begin the crimp.
• Start pump by steadying hose with one
hand while pressing and holding
the power “on”switch with the other
hand, which extends the ram (see pump
operation manual for switch location).
8.
Remove hose assembly.
• While holding hose, lightly lift bottom
of die set to release hose assembly.
• Remove hose assembly.
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MobileCrimp
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11
Measuring and
Adjusting the
Crimp Diameter
NOTE :
DO NOT measure on top of part number stamps.
1.
Measure the crimp diameter.
When using 21 and 22 Dies
• Using Gates “21/22” dial calipers
(Product No. 7369-1320, Part No. 78217)
measure halfway between ridges (Fig. 1).
To be sure crimp diameter is being
properly measured, mark a crimp flat.
Beginning with that flat, count 9 flats to
get the diameter. Be sure caliper blades
DO NOT touch ridges. (See Photo 3.)
PHOTO 3
2.
Check crimp diameter.
• The measured crimp diameter must be
within 0.010"of the published crimp
diameter. If not, the hose assembly
cannot be used, and adjustment will
be required.
3.
FIG. 1
• Measure halfway between
the ends of crimped portion
of the ferrule (Fig. 2).
Adjust the crimp diameter
(if necessary).
• Check top of die set and the surfaces
of the pressure plate for any debris
(metal chips, dirt, etc.). Debris may
cause some variation in crimp diameter.
FIG. 2
When NOT using 21 and 22 Dies
• Using Gates dial calipers
(Product No. 7369-0320,
Part No. 78215) which
are notched to clear
ridges, measure halfway
between ridges (Sketch
1). Be sure caliper fingers
DO NOT touch ridges or
part number stamps.
(See Photo 3.)
• If necessary, clean the surfaces and
lightly lubricate with Molykote.
4.
Multiple crimps.
• When crimping multiple assemblies,
check every tenth crimp to ensure
diameter is within acceptable range
(± 0.010").
CRIMP DIA.
CALIPER
RIDGES
SKETCH 1
• Measure halfway
down the crimped
portion of the ferrule
(Sketch 2).
CRIMP
DIA.
SKETCH 2
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MobileCrimp
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Maintenance
• Inspect the die links, springs and shoulder screws monthly to see if they are
broken, cracked or missing. These conditions may affect crimp quality. Replace
if necessary.
This crimper requires minimal maintenance.
However, the following practices are
recommended to ensure maximum
reliability and service.
Lubricate.
• Using the small brush and Molykote,
apply a light coat to the inside surface
of the die cone whenever it becomes
shiny.
Inspect hose assembly.
• Inspect hose assembly connecting the
crimper and pump monthly (more often
with severe use).
Check oil level.
• Check the hydraulic oil level in the
pump reservoir after each 10 hours of
use (see pump operation manual for
instructions).
• Check nylon sleeve for cuts or abrasion.
• If sleeve is damaged, check hose for
damage.
• If hose has any signs of damage, replace
immediately. A damaged hose may rupture
and cause serious injury.
• If the oil is more than 1/2" below the
top, add a high-grade hydraulic oil such
as Mobil DTE 25 until within 1/2" of the
top of the reservoir.
• If hydraulic oil is present on the hose
assembly, serious damage may exist.
Replace immediately.
Change the oil.
(NOTE: Frequency depends on the
pump’s general working conditions,
severity of use and overall cleanliness.)
Calibration.
• None required.
• For general shop conditions, change
oil every 300 hours. For field/mobile
conditions, more frequent changes are
required.
• Drain, clean and refill the reservoir
per pump operating instructions with
a high-grade hydraulic oil such as Mobil
DTE 25 until within 1/2" of the top of
the reservoir.
Inspect die sets, pressure plate
and spacers.
• Periodically inspect the surfaces of die
sets, pressure plate and spacers for
debris (metal chips, dirt, etc.) or damage.
• If debris is present, clean and lightly
lubricate. If damaged, replacement is
required (see parts list for ordering
information).
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MobileCrimp
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4 20
13
Troubleshooting
All equipment is tested for proper performance before it is shipped from the factory.
However, if you experience any difficulties,
check the list below to help restore equipment to proper operating standards.
Problem
Correction
• Ram will not fully extend.
• Check hydraulic oil level in pump reservoir.
• Hydraulic oil temperature must be within
+40º F and +120º F.
• Unplug pump from electrical outlet.
(WARNING: pump must be unplugged
to avoid risk of injury.)
• Ram will not retract.
• Slowly and carefully loosen hose at pump.
Be prepared to catch oil as it escapes. If
ram retracts, pump valve may be stuck or
need replacement.
• Pump motor will not start.
• Check electrical connections.
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Replacement
Parts List
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*Not shown
MobileCrimp
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15
Two-Year Limited Warranty on Equipment
For two years from the date of shipment of the equipment to the original user, The Gates
Rubber Company will, at its option, replace or repair any unit which proves to be defective
in material or workmanship, or both, at no cost to the original user of the equipment. This
is the exclusive remedy. THERE IS NO OTHER EXPRESS OR IMPLIED WARRANTY. ALL
INCLUDING THOSE OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, ARE LIMITED TO ONE YEAR FROM DATE OF SHIPMENT OF THE EQUIPMENT
TO THE ORIGINAL USER. LIABILITY FOR CONSEQUENTIAL AND INCIDENTAL DAMAGES UNDER ANY AND ALL WARRANTIES IS EXCLUDED TO THE EXTENT EXCLUSION IS PERMITTED BY LAW. Some states do not allow the exclusion of incidental or
consequential damages, and some states do not allow limitations on how long an implied
warranty lasts, so the above limitation and exclusion may not apply to you. This warranty
gives you specific legal rights and you may also have other rights which vary from state to
state. For warranty service, contact Service Department, The Gates Rubber Company, 990
S. Broadway, P.O. Box 5887, Denver, Colorado 80217.
How to Order
Repair Parts
For selling prices on inventoried parts, refer to
Hydraulic Power Crimp Equipment and Parts List
Price Schedule. Selling prices for parts not shown
in these lists will be furnished on request, or parts
will be shipped at prevailing prices and you will
be billed accordingly. For information regarding
prices, contact your local Gates representative or
The Gates Rubber Company, 990 South Broadway,
P.O. Box 5887, Denver, Colorado 80217.
All parts for MobileCrimpTM 4-20 machine listed
in current replacement parts price sheets can be
ordered directly from The Gates Rubber Company,
Iola Distribution Center, 999 Michigan Ave.,
P.O. Box 606, Iola, KS 66749,
Phone (316) 365-6961.
When returning inoperable equipment, contact
your Gates sales representative and request a
return goods authorization form. Fill out and
send to:
When ordering, be sure to include the following
information:
1. Name of unit shown on front.
The Gates Rubber Company
ATTN: Service Department
Unit 29 Receiving
901 S. Broadway
Denver, Colorado 80209-4009
2. Product number of parts needed.
3. Description of parts needed.
4. Quantity of parts needed.
5. Serial number of machine.
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MMoboibleC
ileCririmmpp
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4422
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The world’s most trusted name in belts, hose and hydraulics.
The Gates Rubber Company
P.O. Box 5887
Denver, Colorado 80217-5887
428-7561 (Auto)
35032-PS (Ind)
9/02